Protective textile sleeve having high edge abrasion resistance and method of construction

ABSTRACT

A textile sleeve for protecting elongate members and method of construction thereof is provided. The sleeve includes both monofilament and multifilament yarns woven in both warp and fill directions. The warp yarns are woven in a warp-faced pattern with the fill yarns. As such, the warp yarns float over 2 or more of fill yarns. The warp monofilaments provide the sleeve with increased abrasion resistance, while the warp multifilaments provide the sleeve with increased flexibility and coverage protection to protect elongate members within a cavity of the sleeve. The fill monofilaments provide the sleeve with increased abrasion resistance and the fill multifilaments provide the sleeve with increased flexibility and coverage protection. The method includes weaving the warp and fill yarns in one of an open or closed wall construction. The method can include heat-setting the monofilament fill yarns to bias the open wall into a self-closing tubular configuration.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application Ser.No. 61/032,663, filed Feb. 29, 2008, which is incorporated herein byreference in its entirety.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates generally to protective sleeving for elongatemembers, and more particularly to woven textile sleeves.

2. Related Art

Elongate members, such as wires or wire harnesses commonly requireprotection from potential external sources of abrasion. Accordingly, itis common to dispose a protective sleeve over the elongate members toprovide protection against damage from abrasion and other potentiallyharmful conditions, such as contamination. It is known to use convoluteor corrugated tubing to protect elongate members against abrasion,particularly if the potential for abrasion is relatively severe, such asfrom passing the elongate members through an opening having sharpcorners or edges. Unfortunately, although corrugated tubing can providethe relatively good protection against abrasion, the tubing isrelatively costly to manufacture, and it is typically stiff and thus, itcan be difficult to route over serpentine paths or around corners. Inaddition, the rigid walls of the corrugated tubing can provide aninternal source of abrasion to the very elongate members it is intendedto protect, particularly if contaminates, such as oil and sand, comebetween the elongate members and the inner wall of the tubing.

As a result of the drawbacks of corrugated tubing, of which some arediscussed above, other types of protective tubing are used to protectelongate members, such as textile sleeves. Textile sleeves are typicallymuch easier to route over serpentine paths and can be less expensive tomanufacture than corrugated sleeving. In addition, textile sleeves aretypically softer and thus, present less of a likelihood of causingabrasion damaged to the elongate members. However, a recognized drawbackto textile sleeves is that they have a reduced capacity to provideabrasion resistance protection to the elongate members from an externalsource of abrasion, particularly sharp corners and edges. Sharp surfacesthat come into contact with the textile sleeve wall in a generallyperpendicular direction are particularly damaging to the fabric of thesleeve. Over time, if the wall is cut by the sharp edge, then theelongate members become exposed and unprotected.

Accordingly, benefits and drawbacks are associated with both hardshelled tubing, such as convolute metal or plastic tubing and textilesleeves. What is needed is a protective sleeving that provides thebenefits of both, while eliminating their potential drawbacks.

SUMMARY OF THE INVENTION

A textile sleeve for protecting elongate members includes bothmonofilament and multifilament yarns woven in a lengthwise or warpdirection and a widthwise or fill direction. The warp multifilaments andmonofilaments are woven in a warp-faced pattern with the fillmultifilament and monofilament yarns. As such, the warp multifilamentsand monofilaments float over 2 or more of fill yarns to provide thesleeve with increased flexibility. The warp monofilaments provide thesleeve with increased abrasion resistance, while at the same time, thewarp multifilaments provide the sleeve with increased flexibility andcoverage protection for the elongate members within a cavity of thesleeve. The fill monofilaments provide the sleeve with increasedabrasion resistance and the fill multifilaments provide the sleeve withincreased flexibility and coverage protection.

In accordance with another aspect of the invention, the warpmultifilament and monofilament yarns are woven in a twill, warp-facedpattern.

In accordance with another aspect of the invention, the warp-faced twillpattern can be balanced, thereby having the warp yarns floating over andunder the same number of fill yarns.

In accordance with another aspect of the invention, the warp-faced twillpattern can be imbalanced, thereby having the warp yarns floating overone number of fill yarns and being woven under a different number offill yarns.

In accordance with another aspect of the invention, the multifilamentand monofilament fill yarns can be dual inserted.

In accordance with yet another aspect of the invention, the warpmultifilament yarns and the warp monofilament yarns can be incorporatedin a ratio of about 2:1, respectively.

A textile sleeve constructed in accordance with the invention has a highlevel abrasion resistance to external sources of abrasion, such as sharpedges, while also providing increased levels of abrasion resistance tothe elongate members within the sleeve, such as from contaminants thatbecome between the sleeve and the elongate members. The sleevesconstructed in accordance with the invention, while providing highlevels of protection against abrasion, are also relatively flexible toallow them to be laid over winding paths and around sharp corners. Inaddition, sleeves constructed in accordance with the invention areeconomical in manufacture and in use, and have a long and useful life.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects, features and advantages of the invention willbecome readily apparent when considered in connection with the followingdetailed description of presently preferred embodiments and best mode,appended claims and accompanying drawings, in which:

FIG. 1 is a schematic perspective view of a protective sleeveconstructed in accordance with one presently preferred embodiment shownprotecting elongate members;

FIG. 2 is a schematic perspective view of a protective sleeveconstructed in accordance with another presently preferred embodimentshown protecting elongate members;

FIG. 3 is a schematic partial view of an encircled area 3 of a wall ofthe sleeves of FIGS. 1 and 2; and

FIG. 4 is an enlarged schematic partial side view showing a weavepattern of the walls of FIG. 3.

DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS

Referring in more detail to the drawings, FIGS. 1 and 2 illustratetextile sleeves 10, 110, respectively, constructed in accordance withpresently preferred embodiments for protecting elongate members 12, suchas a wire harness, for example. Each of the sleeves 10, 110 is discussedhereafter using the same reference numerals to identify the structure oftheir respective walls 14, with the notable difference between thesleeves 10, 110 being that the sleeve 10 is woven having an “open” wallconstruction, while the sleeve 110 is woven having a “closed” wallconstruction. The wall 14 is woven from both monofilament andmultifilament yarns, wherein the monofilament and multifilament yarnsare woven both in a lengthwise or warp direction and a widthwise or filldirection extending about a circumference of the sleeves 10, 110. Asbest shown in FIG. 4, the warp multifilament yarns 16 and the warpmonofilaments yarns 18 are woven in a warp-faced pattern in interlacedfashion with the fill multifilament yarns 20 and the fill monofilamentyarns 22. As such, the warp multifilament yarns 16 and warp monofilamentyarns 18 both float over 2 or more of the fill yarns 20, 22 to providethe sleeve 10 with increased flexibility. The warp monofilament yarns 18can be provided of any suitable material, such as polyester, e.g. PET,and in any desired diameter to provide the sleeve with the desired levelof abrasion resistance, such as from edges or other surfaces abuttingthe sleeve. The warp multifilament yarns 16 can be provided of anysuitable material, such as polyester, e.g. PET, and having any desiredtext to provide the sleeve with increased flexibility and coverageprotection for the elongate members 12 being protected within a cavity24 of the sleeves 10, 110. The warp and fill monofilament yarns 18, 22provide the sleeves 10, 110 with increased abrasion resistance and thewarp and fill multifilament yarns 16, 20 provide the sleeves 10, 110with increased flexibility, softness and coverage protection to protectthe elongate members 12.

As shown in FIG. 1, the wall 14 of the sleeve 10 is woven having an“open” wall construction, thereby having a axially extending, lengthwiseslit 26 extending along a longitudinal axis 27 over the full length ofthe sleeve 10. Otherwise, as shown in FIG. 2, the wall 14 of the sleeve110 is woven having a “closed”, circumferentially seamless construction,thus having a circumferentially continuous and uninterrupted wall. Ineither case, the sleeve 10 can be constructed on either narrow or broadlooms, as desired. Wherein the sleeve is constructed having an open wallconfiguration, opposite edges 28, 30 of the wall 14 are preferablyarranged in overlapping relation to one another to completelyencapsulate the elongate members 12 about the circumference of thesleeve within the sleeve cavity 24. Otherwise, the wall 14 can beconstructed as a self-wrapping wall, wherein the wall 14 is self-curlingto take on its tubular configuration absent some external force causingthe wall 14 to be opened along its length. The bias imparted in theself-wrapping wall 14 can be imparted via a heat-setting process,wherein the fill monofilament yarns of the sleeve 10 are heat-set totake on a predetermined self-wrapping tubular configuration and/or bytensioning the yarns during the weaving process. Otherwise, the wall 14could be wrapped and fastened in its tubular configuration using anysuitable fastening mechanism, such as tape, a hook and loop mechanism,snaps, or the like.

As shown in FIG. 3, the wall 14 can be constructed using a twill weavepattern, wherein the wall is represented here, by way of example andwithout limitation, as having a balanced 2×2 left hand, warp-faced twillweave pattern. It should be recognized that the weave pattern could bedifferent than illustrated. Accordingly, the weave pattern could beprovided as a left or right hand pattern, and further, the weave patterncould be imbalanced, wherein the warp yarns 16, 18 could float over onenumber of the fill yarns 20, 22, such as 2, 3 or 4 fill yarns, forexample, and be woven under a different number of the fill yarns.

The warp yarns 16, 18 in one presently preferred embodiment are providedin a ratio of about 2 warp multifilament yarns 16 to 1 warp monofilamentyarn 18 to provide the sleeve 10 with the desired abrasion resistance,while also providing the sleeve 10 with flexibility, such that thesleeve can be readily routed around corners. For example, in a sleevehaving an unfolded, flattened tape width of about 67 mm, the number ofends of warp multifilament yarns 16 can be about 70-80, while the numberof ends of warp monofilament yarn 18 can be about 35-40. In thisexample, and without limitation, the multifilament yarns 16 can beprovided having about a 900-1400 text and the monofilament yarns 18 canbe provided having about a 0.20-0.30 mm diameter.

As best shown in FIG. 4, the weft or fill yarns 20, 22 are provided in adual insertion fashion to provide pairs of the fill yarns spaced axiallyfrom one another with one fill yarn 20 being adjacent and closelyabutting another fill yarn 22. In the 67 mm wide embodiment describedabove, the fill yarns 20, 22 are inserted having a picks per inch (PPI)of about 14-18, wherein the same types and sizes of yarn can be used asused for the warp yarns 16, 18, if desired. The fill monofilament yarns22 provide the sleeve 10 with an increased ability to resist abrasion,and possibly a self-curling bias, as discussed above, while the fillmultifilament yarns 20 provide the sleeve 10 with an increasedflexibility and coverage to further protect against the ingress ofcontamination into the sleeve cavity 24.

In a test performed to compare the abrasion resistance between acorrugated tube, a prior art textile sleeve and a sleeve 10 constructedin accordance with the invention, the following test results wereobtained.

Abrasion test Result (Size: 13 mm) [Unit: cycle] Corrogated Prior ArtPresently Preferred Sample Tube Textile Sleeve Embodiment 1 4,000 29311,700 2 5,000 416 16,355 3 12,666 Average 4,500 355 13,574 Mass: 400 gThickness: 2 mm Stroke width: 51 mm Frequency: 150 cycles/min

As illustrated, the corrugated tube demonstrated a resistance toabrasion over an average of 4,500 cycles, the prior art textile sleevedemonstrated a resistance to abrasion over an average of 355 cycles, andthe sleeve 10 demonstrated a resistance to abrasion over an average of13,574 cycles. Accordingly, the sleeve 10 far outperformed both thecorrugated tube (about 3 times as great of an ability to resistabrasion) and the prior art textile sleeve (about 38 times as great ofan ability to resist abrasion). It should be noted that the prior arttextile sleeve was woven having only monofilaments in the warp directionand only multifilaments in the fill direction.

Obviously, many modifications and variations of the present inventionare possible in light of the above teachings. For example, it needs tobe understood that the sleeves 10, 110 can be constructed other than asexpressly described above in the presently preferred embodiment, andthat other types and sizes of yarns can be used in the construction ofthe sleeves 10, 110. It is, therefore, to be understood that within thescope of the appended claims, the invention may be practiced otherwisethan as specifically described.

1. A textile sleeve for protecting elongate members, comprising: anelongate wall having warp multifilament yarns and warp monofilamentyarns woven with fill multifilament yarns and fill monofilament yarns,said warp multifilament yarns and said warp monofilament yarns beingwoven in a warp-faced pattern in relation to said fill multifilamentyarns and said fill monofilament yarns.
 2. The textile sleeve of claim 1wherein each of said fill multifilament yarns is inserted with one ofsaid fill monofilament yarns to form dual inserted pairs of fill yarns.3. The textile sleeve of claim 2 wherein about 2 of said warpmultifilament yarns are provided for every 1 of said warp monofilamentyarns.
 4. The textile sleeve of claim 2 wherein said warp multifilamentyarns and said warp monofilament yarns are woven in a balanced twillweave.
 5. The textile sleeve of claim 1 wherein said wall is a closed,circumferentially continuous wall.
 6. The textile sleeve of claim 1wherein said wall is an open wall having a slit provided by oppositeedges extending along a longitudinal axis of said sleeve.
 7. The textilesleeve of claim 6 wherein said fill monofilament yarns are heat-set intoa self-biased curled configuration to bring said opposite edges inoverlapping relation with one another.
 8. A method of constructing atextile sleeve for protecting elongate members, comprising: weavingmultifilament yarns and monofilaments yarns with one another with aplurality of said multifilament yarns and said monofilament yarnsproviding warp yarns extending along a length of the sleeve and aplurality of said multifilament yarns and said monofilament yarnsproviding fill yarns extending about a circumference of the sleeve. 9.The method of claim 8 further including inserting said fill yarns inpairs with one of said fill monofilament yarns being inserted with oneof said fill multifilament yarns.
 10. The method of claim 9 furtherincluding weaving about 2 of said warp multifilament yarns for every 1of said warp monofilament yarns.
 11. The method of claim 9 furtherincluding weaving said warp yarns in a warp-faced pattern.
 12. Themethod of claim 11 further including weaving said warp yarns in a twillpattern.
 13. The method of claim 12 further including weaving said warpyarns in a balanced twill pattern.
 14. The method of claim 9 furtherincluding weaving said sleeve having a wall with a closed,circumferentially continuous wall.
 15. The method of claim 9 furtherincluding weaving said sleeve having a wall with a slit provided byopposite edges extending along a longitudinal axis of said sleeve. 16.The method of claim 16 further including heat-setting said fillmonofilament yarns into a self-biased curled configuration to bring saidopposite edges in overlapping relation with one another.